SupplierBusiness : Powertrain - New Technologies & Strategies

Table of Contents

Introduction

Industry Drivers

• Legislation and regulation
• Sulphur

Gasoline Engine Technology

• Fuel efficiency
• Engine technology development
• Engine downsizing
• The 2/4SIGHT engine
• Torque enhancement system (VTES)
• Variable compression ratios
• Valve technology
• Variable valve technology
• Electro-mechanical valve control
• Cylinder shutoff - Variable Displacement Engine (VDE) or Displacement on Demand
• Combustion systems
• Gasoline Direct Injection
• Spray guided injection
• Alternative engine technologies
• The MUSIC engine
• The Duke Engine
• The Pivotal Engine
• Homogeneous charge compression ignition (HCCI)
• The Daimler DiesOtto concept

Diesel Engine Technology

• Weight reduction and new powertrain materials
• Commonrail injection
• Bosch' s third generation commonrail system
• Commonrail for commercial vehicles
• Piezo technology
• Pistons
• Compacted Graphite Iron (CGI)
• Diesels in the US
• The economic benefits of engine families
• Summary and outlook

Turbocharging

• Turbocharger Sectors
• Heavy Duty
• Light duty
• Performance
• Superchargers
• Turbocharging Versus Supercharging
• Wastegated turbochargers
• Turbocompounding
• Charged Air Coolers (CACs)
• Compressors
• Compressor mapping
• Bearing Systems
• Radial Bearing System
• Micro turbocharging
• Variable geometry
• Multiple Turbochargers
• Electronic controls and new materials
• Titanium Compressor Impellers
• Assisted turbocharging

Exhaust after-treatment

• Gasoline (Petrol) Engine Emissions
• Diesel Engine Emissions
• Exhaust Gas Recirculation (EGR)
• Selective Catalytic Reduction (SCR)
• System design

Alternative powertrains

• Hybrid Technology
• Types of hybrid vehicle
• Micro Hybrids
• Electronic components
• Series hybrids
• Parallel hybrids
• Series/Parallel hybrids
• Full Hybrid
• Mild or Assist Hybrids
• Plug-In or Dual-Mode hybrids
• Hybrid transmissions
• One-Mode and Two-Mode Hybrids
• Regenerative braking
• Electric motors
• AC Motors
• DC Motors
• Synchronous motors
• Switch reluctance machines
• Battery Technology
• Lead acid
• Nickel-metal hydride (NiMH)
• Sodium nickel chloride (NaNiCl)
• Lithium-ion
• Li-ion technology improvements
• Supercapacitors and ultracapacitors

Alternative fuels

• Ethanol
• Liquefied Petroleum Gas (LPG) and Compressed Natural Gas (CNG)
• Biofuels
• Biofuels' compatibility with today' s engines
• Biodiesel
• Hydrogen
• The hydrogen internal combustion engine
• Hydrogen enriched compressed natural gas (HCNG)
• Fuel cell vehicles
• The different methods
• Liquefied hydrogen
• Compressed hydrogen
• Methanol
• Gasoline reformation
• Metal hydrides
• Nanotubes
• Sodium borohydride
• Cost factors
• Fuel cell advantages
• Future trends

OEM Strategy

TABLE OF FIGURES

• Figure 1: Contribution to CO2 reduction
• Figure 2: Urban road transport NOx emissions 1990 - 2015
• Figure 3: Permitted emissions for cars by class.
• Figure 4: Specific emissions targets
• Figure 5: Comparison of EU light vehicles against new proposed EU CO2 limits
• Figure 6: Current car manufacturers' status against EU target
• Figure 7: International Sulphur content regulation 2007
• Figure 8: Technology roadmaps for gasoline engines focused on CO2 reduction
• Figure 9: Cost/ benefit of future powertrain choices
• Figure 10: 2/4SIGHT prototype engine
• Figure 11: 2/4SIGHT engine concept
• Figure 12: VCR engine efficiency at various power levels
• Figure 13: Nissan' s VVEL system
• Figure 14: A cam-less engine using electro-mechanical valve control on test at Lotus.
• Figure 15: Valeo' s e-valve system
• Figure 16: A comparison of wall guided and spray guided direct injection
• Figure 17: Cylinder head design layout for a four cylinder engine
• Figure 18: A 3 litre equivalent Duke Engine
• Figure 19: Water-cooled pivotal piston engine
• Figure 20: The effect of diesel engine downsizing on fuel consumption
• Figure 21: Continental' s piezo injector.
• Figure 22: Delphi' s HP HD Diesel Commonrail System
• Figure 23: A comparison of direct acting injectors versus servo-hydraulic injector spray patterns
• Figure 24: US diesel and gasoline prices in comparison with the WTI crude index
• Figure 25: Supercharged Audi 3.0L V6 Engine
• Figure 26: Scania 12 litre Euro IV engine with EGR and turbocompounding
• Figure 27: Compressor map of a turbocharger for passenger car applications
• Figure 28: Holset VGT"! Turbocharging Technology
• Figure 29: Tri-turbo concept from Mercedes-Benz
• Figure 30: BMW bi-turbo
• Figure 31: Turbocharging technologies for high pressure charging
• Figure 32: A comparison between 1975 and 2009 passenger car exhaust system
• Figure 33: A Three-way catalytic converter
• Figure 34: Heated TWC
• Figure 35: NOx /particulates trade-off in cooled and non-cooled EGR systems
• Figure 36: A schematic illustrating SCR
• Figure 37: Diesel Particulate Filter
• Figure 38: Diesel exhaust after-treatment system schematic
• Figure 39: Ratio of engine and motor operation in the hybrid system
• Figure 40: Continental' s ISAD Unit
• Figure 41: Stop-start (micro-hybrid) production forecast
• Figure 42: Delphi Belt Alternator Starter
• Figure 43: Hybrid electric vehicle drive configurations
• Figure 44: One-Mode Hybrid Input-Split EVT
• Figure 45: Two-Mode Hybrid Input-Split EVT
• Figure 46: One-Mode Hybrid Input-Split EVT
• Figure 47: Two-Mode Hybrid with Input-Split and Compound-Split EVT Modes
• Figure 48: Two mode hybrid transmission
• Figure 49: Regenerative Braking System
• Figure 50: EV motors
• Figure 51: Switch reluctance machines
• Figure 52: Battery price trend forecast
• Figure 53: Energy storage overview
• Figure 54: Battery technology evolution
• Figure 55: A typical Zebra battery module
• Figure 56: Lithium-ion battery pack
• Figure 57: Energy density versus output density in battery systems
• Figure 58: A Ragone plot showing energy density vs power density for various energy-storage devices
• Figure 59: CNG filling stations in Europe.
• Figure 60: Bi-fuel system components
• Figure 61: A SunLine Tranist Agency "SunBus" with Cummins Westport 5.9-litre B Gas Plus engine, refuelling with HCNG
• Figure 62: World biofuel targets
• Figure 63: First and second generation biofuels
• Figure 64: Well-to-wheel analysis for biofuels
• Figure 65: Pros and cons of first and second generation biofuels
• Figure 66: OEM manufactured CNG/ LPG engine options are limited
• Figure 67: Comparison of fuel cell technologies
• Figure 68: Mercedes-Benz B Class Fuel Cell research vehicle
• Figure 69: Ballard' s fuel cell stack
• Figure 70: Ford fuel cell components
• Figure 71: Ford' s Focus fuel cell vehicle
• Figure 72: Regional CO2 reduction performance
• Figure 73: Regional CO2 reduction performance
• Figure 74: Average European corporate CO2 output 2006
• Figure 75: Gasoline and diesel paths to lower CO2 emissions
• Figure 76: Passenger car powertrain timeline
• Figure 77: Gasoline and diesel CO2 reduction effects
• Figure 78: Passenger car electrification timeline
• Figure 79: Ford sustainable technologies migration plan
• Figure 80: OEM CO2 reduction strategy summary
• Figure 81: GM advanced propulsion strategy
• Figure 82: GM diesel technology programme
• Figure 83: GM gasoline technology programme